Method of forming an electrical connection between an electrochemical cell and a meter

ABSTRACT

A method of forming an electrical connection between an electrochemical cell and a meter is provided. According to the method, an electrical connection is made between a meter, by means of a wedge-shaped connector with upper and lower conductive surfaces, and an electrochemical cell comprising a first substrate with a first electrically conductive coating and a second substrate with a second electrically conductive coating, the electrically conductive coatings being disposed to face each other in a spaced apart relationship by an insulating spacer. The meter further includes a pivot point for rotating the wedge connector on the pivot point.

RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.60/345,743, filed Jan. 4, 2002.

FIELD OF THE INVENTION

The present invention relates to electrochemical cells including aconnector which mates with a meter connection device to provideelectrical connection to meter circuitry.

BACKGROUND OF THE INVENTION

Miniature electrochemical cells are useful in applications such aschemical sensing wherein the electrodes of a strip element interfacewith an electronic device. The electronic device, often termed a meter,measures the electrical response of the strip element to the sample andcan also supply power to the strip element to perform a test. In orderto perform these functions, the strip element electrodes must be able tomake electrical connection to the meter circuitry. Such an electricalconnection may be made via a connection device on the meter which mateswith areas on the strip element in electrical communication with theelectrochemical cell electrodes.

In configurations of electrochemical cells as disclosed in WO 98/43073,U.S. Pat. No. 5,437,999, EP 0 964 059 A2, WO 00/20626, an upper and alower electrode face oppose one another with an electrically insulatinglayer between them. The electrodes in such a configuration are typicallyformed on separate substrates that are assembled during manufacture ofthe electrochemical cell. This configuration presents difficulties inmanufacture when forming a part by which the strip element electrodesare connected to the meter circuitry, as it is different from the usualconnection configuration where the connection areas are all on the sameplane.

The issue of connection areas in different planes has been addressed invarious ways. In WO 98/43073, a method and device are disclosed whereincut-outs are formed in one of the electrode layers and in the insulatinglayer to expose an area of the underlying electrode layer which can beused as an connection area. In U.S. Pat. No. 5,437,999 and WO 00/20626,a method an device are disclosed wherein a flap is formed on oneelectrode layer with a corresponding cut-out in the other electrodelayer to expose a suitable connection area. In this configuration, theinsulating layer is cut short so as not interfere with the connectionarea.

In EP 0 964 059 A2, the insulating layer is cut short, and a hole isformed in the upper substrate in order to expose a connection area atthe base of the well that is formed. The well may be filled with aconductive material and a contact made with the conductive material atthe top of the filled well, thus bringing the connection areas onto oneplane.

A drawback to these configurations is that they require features on morethan one of the cell layers to be in registration with one another whenthe layers are assembled into a working device. This createsdifficulties in manufacturing the devices and limits the manufacturingtechniques that can be used. In particular, for costs and throughputconsiderations, it is often desirable to manufacture the strip elementsin a continuous web form. When using continuous webs it is oftendifficult to reliably achieve the down-web registration of repeatingfeatures formed on different layers prior to a lamination step. Oftenthis requires expensive control systems and a relatively fragilefabrication process, if it is possible at all.

SUMMARY OF THE INVENTION

Electrochemical cell connectors that are suitable for use in conjunctionwith opposing electrode electrochemical cells, and methods of formingthem, that require no down-web registration steps prior to lamination ofthe layers are desirable. The preferred embodiments provide suchelectrochemical cell connectors and methods.

In a first embodiment, an electrochemical cell is provided, theelectrochemical cell adapted for electrical connection with a meter, thecell including a first insulating substrate carrying a firstelectrically conductive coating, a second insulating substrate carryinga second electrically conductive coating, and an insulating spacer layerdisposed therebetween, the electrically conductive coatings beingdisposed to face each other in a spaced apart relationship, wherein anedge of the first insulating substrate carrying the first electricallyconductive coating extends beyond an edge of the second insulatingsubstrate carrying the second electrically conductive coating and beyondan edge of the insulating spacer layer, and wherein the edge of thesecond insulating substrate carrying the second electrically conductivecoating extends beyond the edge of the insulating spacer layer.

In an aspect of the first embodiment, the first insulating substratecarrying the first electrically conductive coating includes an aperturein a portion of the first insulating substrate carrying the firstelectrically conductive coating that extends beyond the edge of theinsulating spacer, such that an area of the second electrode layer isexposed so as to provide a surface for forming an electrical connectionwith a meter via the aperture.

In an aspect of the first embodiment, the cell further includes anadditional insulating spacer layer, the additional spacer layer disposedbetween the first electrically conductive coating and the secondelectrically conductive coating, wherein the insulating spacer layer andthe additional spacer layer are situated on opposite sides of theaperture.

In a second embodiment, an electrochemical cell is provided, theelectrochemical cell adapted for electrical connection with a meter, thecell including a first insulating substrate carrying a firstelectrically conductive coating, a second insulating substrate carryinga second electrically conductive coating, and an insulating spacer layerdisposed therebetween, the electrically conductive coatings beingdisposed to face each other in a spaced apart relationship, wherein anedge of the first insulating substrate carrying the first electricallyconductive coating extends beyond an edge of the second insulatingsubstrate carrying the second electrically conductive coating and beyondan edge of the insulating spacer layer, and wherein the first insulatingsubstrate carrying the first electrically conductive coating and theinsulating spacer layer include an aperture, such that an area of thesecond electrode layer is exposed so as to provide a surface for formingan electrical connection with a meter via the aperture.

In a third embodiment, an electrochemical cell is provided, theelectrochemical cell adapted for electrical connection with a meter, thecell including a first insulating substrate carrying a firstelectrically conductive coating, a second insulating substrate carryinga second electrically conductive coating, and an insulating spacer layerdisposed therebetween, the electrically conductive coatings beingdisposed to face each other in a spaced apart relationship, wherein aportion of the first insulating substrate carrying the firstelectrically conductive coating extends beyond an edge of the secondinsulating substrate carrying the second electrically conductive coatingand beyond an edge of the insulating spacer layer, and wherein a portionof the first insulating substrate carrying the first electricallyconductive coating and a portion of the insulating spacer are removed soas to form a notch, the notch situated adjacent to the edge of thesecond insulating substrate carrying the second electrically conductivecoating and the edge of the insulating spacer layer, such that an areaof the second electrode layer is exposed so as to provide a surface forforming an electrical connection with a meter.

In a fourth embodiment, a method for forming an electrical connectionbetween an electrochemical cell and a meter is provided, the methodincluding the steps of: providing an electrochemical cell, theelectrochemical cell comprising a first insulating substrate carrying afirst electrically conductive coating, a second insulating substratecarrying a second electrically conductive coating, and an insulatingspacer layer disposed therebetween, the electrically conductive coatingsbeing disposed to face each other in a spaced apart relationship,wherein an edge of the first insulating substrate carrying the firstelectrically conductive coating extends beyond an edge of the secondinsulating substrate carrying the second electrically conductive coatingand beyond an edge of the insulating spacer layer, and wherein the edgeof the second insulating substrate carrying the second electricallyconductive coating extends beyond the edge of the insulating spacerlayer; providing a meter, the meter including a wedge, the wedgeincluding an upper wedge conductive surface and a lower wedge conductivesurface, the conductive surfaces in electrical communication with themeter; and inserting a portion of the electrochemical cell into themeter, whereby the wedge is inserted between the portion of the firstinsulating substrate carrying the first electrically conductive coatingand the portion of the second insulating substrate carrying the secondelectrically conductive coating that extends beyond the edge of theinsulating spacer layer, whereby an electrical connection between thefirst electrically conductive coating and the lower wedge conductivesurface is formed, and whereby an electrical connection between thesecond electrically conductive coating and the upper wedge conductivesurface is formed.

In an aspect of the fourth embodiment, the meter further includes apivot point, wherein the wedge is capable of rotating on the pivotpoint.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 a and 1 b provide schematics of an electrochemical cell whereinelement 2 is offset from the corresponding edge of element 1 so as toexpose the conductive coating on element 1. FIG. 1 a illustrates a topview and FIG. 1 b a cross-section view.

FIGS. 2 a and 2 b provide schematics of an electrochemical cell whereina through hole is cut in element 1 to expose the conductive coating onelement 2 for electrical connection. FIG. 2 a illustrates a top view andFIG. 2 b a cross-section view.

FIGS. 3 a and 3 b provide schematics of an electrochemical cell similarto the cell of FIG. 2, except that an extra portion of element 3 hasbeen inserted between elements 1 and 2. FIG. 3 a illustrates a top viewand FIG. 3 b a cross-section view.

FIGS. 4 a and 4 b provide schematics of an electrochemical cell whereina slot is formed in element 1, which gives access to an area of theconductive coating on element 2. FIG. 4 a illustrates a top view andFIG. 4 b a cross-section view.

FIGS. 5 a and 5 b provide schematics of an electrochemical cell similarto the cell of FIG. 2, except that the edge of element 3 is such that itis situated above element 4 in element 1. FIG. 5 a illustrates a topview and FIG. 5 b a cross-section view.

FIGS. 6 a and 6 b provide schematics of an electrochemical cell similarto the cell of FIG. 4, except that the edge of element 3 is such that itis at least close to the edge of element 1. FIG. 6 a illustrates a topview and FIG. 6 b a cross-section view.

FIG. 7 provides a side view illustrating the splitting of element 1 fromelement 2 in the connector area to allow access for a tongue connectiondevice.

FIG. 8 provides an end view illustrating the splitting of element 1 fromelement 2 in the connector area to allow access for a tongue connectiondevice.

FIG. 9 provides an illustration depicting a strip partially insertedinto an external circuit connector.

FIG. 10 provides an illustration depicting a strip fully inserted intoan external circuit connector.

FIG. 11 provides a side view of an external circuit connector 100.

FIG. 12 provides an illustration depicting a strip partially insertedinto an external circuit connector 100 as illustrated in FIG. 11.

FIG. 13 provides an illustration depicting a strip fully inserted intoan external circuit connector 100 as illustrated in FIG. 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following description and examples illustrate a preferred embodimentof the present invention in detail. Those of skill in the art willrecognize that there are numerous variations and modifications of thisinvention that are encompassed by its scope. Accordingly, thedescription of a preferred embodiment should not be deemed to limit thescope of the present invention.

The preferred embodiments relate to devices and methods for formingelectrode connection areas in electrochemical cells with opposingelectrodes. The devices and methods do not require the registration offeatures formed on different layers prior to the lamination of thelayers. In particular, devices and methods that do not require thedown-web registration of repeating features on different layers duringlamination of continuous webs of devices during manufacture areprovided. The preferred embodiments may be used in conjunction with anysuitable fabrication process, for example, a process wherein discretesections of the layers are laminated together and wherein it isadvantageous to lessen the registration requirements and therefore themanufacturing complexity.

In another embodiment, preferred elements of the port in a meter devicesuitable for use with the disclosed strip connectors are provided.

The basic feature of the electrochemical cells illustrated in FIGS. 1-6is that the edge of at least one electrode layer (herein termed theupper electrode layer) is offset from at least one other opposingelectrode layer (here termed the lower electrode layer) such that anarea of the lower electrode layer overhangs the edge of the upperelectrode layer, thus exposing an area of the lower electrode layersuitable for connection to meter circuitry.

FIGS. 1 to 6 depict views of various preferred embodiments ofelectrochemical cell connectors. FIGS. 1 a, 2 a, 3 a, 4 a, 5 a, and 6 adepict top views of sections of web or card of the assembled layers forvarious embodiments, showing the repeating features. FIGS. 1 b, 2 b, 3b, 4 b, 5 b, and 6 b depict the corresponding cross-sectional views.

In FIGS. 1 to 6, element 1 is the lower electrode layer. This layerconsists of an electrically insulating substrate with an electricallyconductive coating applied to its upper face, wherein the electricallyconductive coating is in electrical contact with at least a firstelectrode of the electrochemical cell.

Element 2 is the upper electrode layer. This layer consists of anelectrically insulating substrate with an electrically conductivecoating applied to its lower face, wherein the electrically conductivecoating is in electrical contact with at least a second electrode of theelectrochemical cell.

Element 3 is an electrically insulating layer which serves to spaceelements 1 and 2 apart. In preferred embodiments, the upper and lowerfaces of element 3 are adhesive and also serve to adhere the layers ofthe device together. In this preferred embodiment, element 3 may consistof a substrate coated with an adhesive. Alternatively it may consist ofjust an adhesive layer.

Element 4 is a cut-out feature in element 1 which, as illustrated inFIGS. 2 to 6, serves to give access to an exposed area of theelectrically conductive coating on the lower face of element 2.

In FIG. 1, one edge of element 2 is offset from the corresponding edgeof element 1, such that an overhanging area of the conductive coating onelement 1 is exposed. In a preferred embodiment, a tongue ofelectrically insulating substrate material with electrically conductivecoatings or layers on its upper and lower faces is inserted betweenelements 1 and 2 to make electrical connection to the meter circuitry.

In FIG. 2, a through hole is cut in element 1 to expose an area of theconductive coating on element 2 for electrical connection. This obviatesthe need for having a connection device inserted between the layers.

The device depicted in FIG. 3 is similar to that depicted in FIG. 2,except that an extra portion of element 3 has been inserted betweenelements 1 and 2. This configuration is desirable if it is likely thatelements 1 and 2 will be pushed together during use and thus create anelectrical short-circuit between the conductive coatings on elements 1and 2.

FIG. 4 depicts an embodiment where a slot has been formed in element 1which gives access to an area of the conductive coating on element 2.

FIG. 5 depicts a similar embodiment to FIG. 2. However in thisembodiment the edge of element 3 is such that it is above element 4 inelement 1. In order for this embodiment to be operable in the preferredembodiment elements 1 and 2 must be laminated or otherwise assembledtogether before element 4 is formed.

FIG. 6 depicts a similar embodiment to FIG. 4. However in thisembodiment the edge of element 3 is such that it is at least close tothe edge of element 1. In this embodiment, it is preferred that elements1 and 2 be laminated or otherwise assembled together before element 4 isformed.

In another embodiment, methods are disclosed for forming electricalconnections to some of the connection devices discussed above.

For the electrochemical cells of the preferred embodiments depicted inFIGS. 2 to 6, it is suitable to use parts for the connection of theconductive coatings on elements 1 and 2 to external circuitry such asthose described in U.S. Pat. No. 6,379,513.

For the embodiment depicted in FIG. 1, a different configuration forexternal connection is desirable. For this embodiment, it is desirableto split element 1 from element 2 in the connector area to allow easieraccess for a tongue connection device. According to this aspect of theembodiment, element 1 is split from element 2 during insertion of thestrip connector into external circuitry connector, e.g., by a blade orwedge-shaped projection, or other suitable splitting device.

FIGS. 7 and 8 show a side view and end view, respectively, thatillustrate the splitting of element 1 from element 2 in the connectorarea to allow access for a tongue connection device. FIGS. 9 and 10 showthis embodiment with a strip partially and fully inserted, respectively,into the external circuit connector.

The external circuit connector 10, depicted in FIGS. 7 to 10, contains achamber 18, which contains cavities 11 and 12 into which element 1 andelement 2, respectively, of the strip can be inserted. One or more wedgeshaped projections 17 on the sidewalls of chamber 18 serve to separatestrip elements 1 and 2 as the strip is inserted into chamber 18. As thestrip is inserted into chamber 18, element 1 first strikes the lowerface of projection 17 and is forced down. This action in concert withthe insertion action serves to further separate element 1 from element 2to allow reliable insertion of element 2 into cavity 12.

A further wedge-shaped projection protrudes from the rear face ofchamber 18. Conducting layers are mounted on the faces 13 and 14 of thisprojection, wherein the two conducting layers are electrically insulatedfrom one another. These layers make electrical contact with theconducting coatings on strip elements 1 and 2. Electrically conductingwires or other conducting tracks 15 and 16 are electrically connected tothe conducting layers on faces 13 and 14 and serve to make connection tothe external circuitry. As one skilled in the art will appreciate, thedevice with surfaces comprising conducting layers 13 and 14 may beconstructed so as to be integral with the projections 17.

A second embodiment is depicted in FIGS. 11 to 13. FIG. 11 shows a sideview of the embodiment. FIGS. 12 and 13 show a side view of theembodiment with a strip partially or fully inserted respectively.

The external circuit connector 100, depicted in FIGS. 11 to 13, containsa chamber 105 which contains a wedge 101 that is able to rotate withinthe chamber 105 around the pivot point 102. The wedge compriseselectrically conductive surfaces, 106 and 107 which are electricallyconnected to external connection points 103 and 104. In its initialposition, the wedge 101 is held either by gravity or a spring tensioningdevice (not shown) such that it is positioned as shown in FIG. 11. Whena strip is inserted into the chamber 105, the lower electrode elementstrikes the lower surface of wedge 101 behind the pivot point 102. Thisaction rotates wedge 101 such that the point of the wedge 101 ispositioned between the upper and lower electrode layers of the strip.Then, as the strip is further inserted into chamber 105, the upper wedgesurface 106 is brought into contact with the conducting coating on theupper strip element. Electrical connection of the conducting coating onthe upper strip element to connection point 103, via conducting surface106 is then achieved, as is electrical connection of the conductingcoating on the lower electrode strip element to connection point 104 viaconducting surface 107.

The advantage of the embodiment shown in FIGS. 11 to 13 is that thepoint of the wedge 101 is automatically positioned between the upper andlower strip electrode elements to ensure reliable connection.

Electrochemical Cells

The electrochemical cell connectors of preferred embodiments aresuitable for use in a variety of electrochemical cells. For example, theconnectors may be used in conjunction with electrochemical cells used asamperometric sensors for the detection and quantification of analytes.

In such applications, the electrodes can be positioned such that theworking electrode is isolated from the counter electrode reactions andreaction products, or positioned such that products of the counterelectrode reaction diffuse to the working electrode where they react.The former type of electrochemical cell is well known in the prior art.The latter type of electrochemical cell is discussed in U.S. Pat. No.6,179,979 and U.S. Pat. No. 5,942,102.

These two electrode configurations vary in that in the isolated case,the counter electrode is positioned far enough away from the workingelectrode such that during the time the cell is being used, products ofelectrochemical reactions at the counter electrode do not reach theworking electrode. In practice, this is typically achieved by aseparation of the working electrode from the counter electrode by atleast a millimeter.

In the non-isolated configuration, the working electrode and the counterelectrode are placed close enough together such that products of theelectrochemical reactions at the counter electrode can diffuse to theworking electrode during the time the cell is being used. These reactionproducts can then react at the working electrode, giving a highercurrent than may be present in the isolated electrode case. In thenon-isolated configuration, the working electrode reactions can bedescribed as coupled to the counter electrode reactions.

Fabricating the Electrochemical Cell

In certain embodiments, the electrochemical cells of preferredembodiments may be fabricated using methods similar to those disclosedin U.S. Pat. No. 5,942,102.

As will be recognized by one skilled in the art, the electrode layersand electrically insulating substrates may be independently selected asdesired, for example, for ease of fabrication, for reducing materialscosts, or to achieve other desirable attributes of the cell orfabrication process. Likewise, the electrode layers may be applied tothe layers of electrically insulating substrates in any suitablepattern, for example, a pattern that only partially covers thesubstrate.

In preferred embodiments, various layers in the cell may be adheredusing a suitable adhesive. Suitable adhesives include, for example, heatactivated adhesives, pressure sensitive adhesives, heat cured adhesives,chemically cured adhesives, hot melt adhesives, hot flow adhesives, andthe like. Pressure sensitive adhesives are preferred for use in certainembodiments where simplification of fabrication is desired. However, inother embodiments the tackiness of pressure sensitive adhesives mayresult in fabrication tool gumming or product tackiness. In suchembodiments, heat or chemically cured adhesives are generally preferred.Especially preferred are the heat-activated and heat-cured adhesives,which can be conveniently activated at the appropriate time.

In certain embodiments, it may be preferred to use a hot melt adhesive.A hot melt adhesive is a solvent-free thermoplastic material that issolid at room temperature and is applied in molten form to a surface towhich it adheres when cooled to a temperature below its melting point.Hot melt adhesives are available in a variety of chemistries over arange of melting points. The hot melt adhesive can be in the form of aweb, nonwoven material, woven material, powder, solution, or any othersuitable form. Polyester hot melt adhesives may be preferred for certainembodiments. Such adhesives (available, for example, from Bostik Corp.of Middleton, Mass.) are linear saturated polyester hot melts exhibitingmelting points from 65° C. up to 220° C. and range from completelyamorphous to highly crystalline in nature. Polyamide (nylon) hot meltadhesives, also available from Bostik, may also be preferred, includingboth dimer-acid and nylon-type polyamide adhesives. Suitable hot meltadhesive chemistries include EVA, polyethylene, and polypropylene.

Alternatively, in certain other embodiments it may be preferred to uselamination techniques to bond certain layers together. Suitablelamination techniques are described in application Ser. No. 09/694,106filed Oct. 20, 2000 entitled “LAMINATES OF ASYMMETRIC MEMBRANES”, nowabandoned, and U.S. Pat. No. 6,596,112. The layers to be laminated areplaced adjacent to each other and heat is applied, whereby a bondbetween the layers is formed. Pressure may also be applied to aid informing the bond. Lamination methods may be preferred to bond any twomaterials capable of forming a bond under application of heat and/orpressure. Lamination is preferred to form a bond between two suitablepolymeric materials.

Suitable electrically resistive materials which may be preferred asspacer layers, as supports for electrode layers, or in other layers inthe cell, include, for example, materials such as polyesters,polystyrenes, polycarbonates, polyolefins, polyethylene terephthalate,glasses, ceramics, mixtures and/or combinations thereof, and the like.Examples of electrically resistive adhesives suitable for use as spaceror support layers include, but are not limited to, polyacrylates,polymethacrylates, polyurethanes, and sulfonated polyesters.

Chemicals for use in the cell, such as redox reagents, lysing agents,buffers, inert salts, and other substances, may be supported on the cellelectrodes or walls, on one or more independent supports containedwithin cell, or may be self supporting. If the chemicals are to besupported on the cell electrodes or walls, the chemicals may be appliedby use of application techniques well known in the art, such as ink jetprinting, screen printing, lithography, ultrasonic spraying, slotcoating, gravure printing, and the like. Suitable independent supportsmay include, but are not limited to, meshes, nonwoven sheets, fibrousfillers, macroporous membranes, and sintered powders. The chemicals foruse in the cell may be supported on or contained within a support.

In a preferred embodiment, the preferred materials within the cell aswell as the materials from which the cell is constructed are in a formamenable to mass production, and the cells themselves are designed for asingle experiment then disposed of. A disposable cell is one that isinexpensive enough to produce that it is economically acceptable onlyfor a single test. A disposable cell is one that may conveniently onlybe used for a single test, namely, steps such as washing and/orreloading of reagents may need to be taken to process the cell after asingle use to render it suitable for a subsequent use.

Economically acceptable in this context means that the perceived valueof the result of the test to the user is the same or greater than thecost of the cell to purchase and use, the cell purchase price being setby the cost of supplying the cell to the user plus an appropriate markup. For many applications, cells having relatively low materials costsand simple fabrication processes are preferred. For example, theelectrode materials of the cells may be inexpensive, such as carbon, ormay be present in sufficiently small amounts such that expensivematerials may be preferred. Screen printing carbon or silver ink is aprocess suitable for forming electrodes with relatively inexpensivematerials. However, if it is desired to use electrode materials such asplatinum, palladium, gold, or iridium, methods with better materialutilization, such as sputtering or evaporative vapor coating, arepreferred as they may yield extremely thin films. The substratematerials for the disposable cells are also preferably inexpensive.Examples of such inexpensive materials are polymers such aspolyvinylchloride, polyimide, polyester and coated papers and cardboard.

Cell assembly methods are preferably amenable to mass production. Thesemethods include fabricating multiple cells on cards and separating thecard into individual strips subsequent to the main assembly steps, andweb fabrication where the cells are produced on a continuous web, whichis subsequently separated into individual strips. Card processes aremost suitable when close spatial registration of multiple features isdesired for the fabrication and/or when stiff cell substrate materialsare preferred. Web processes are most suitable when the down webregistration of features is not as critical and flexible webs may bepreferred.

In certain embodiments, a convenient single use for the electrochemicalcell may be desirable so that users are not tempted to try to reuse thecell and possibly obtain an inaccurate test result. Single use of thecell may be stated in user instructions accompanying the cell. Morepreferably, in certain embodiments where a single use is desirable thecell may be fabricated such that using the cell more than once isdifficult or not possible. This may be accomplished, for example, byincluding reagents that are washed away or consumed during the firsttest and so are not functional in a second test. Alternatively, thesignal of the test may be examined for indications that reagents in thecell have already reacted, such as an abnormally high initial signal,and the test aborted. Another method includes providing a means forbreaking electrical connections in the cell after the first test in acell has been completed.

The Electrodes

In a preferred embodiment wherein the electrochemical cell detects thepresence and/or amount of analyte in the sample, or a substanceindicative of the presence and/or amount of analyte present in thesample, at least one of the electrodes in the cell is a workingelectrode. When the potential of the working electrode is indicative ofthe level of analyte (such as in a potentiometric sensor) a secondelectrode acting as reference electrode is present which acts to providea reference potential.

In the case of an amperometric sensor wherein the working electrodecurrent is indicative of the level of an analyte, such as glucose, atleast one other electrode is preferably present which functions as acounter electrode to complete the electrical circuit. This secondelectrode may also function as a reference electrode. Alternatively, aseparate electrode may perform the function of a reference electrode.

Materials suitable for the working, counter, and reference electrodesare compatible with any reagents or substances present in the device.Compatible materials do not substantially react chemically with othersubstances present in the cell. Examples of such suitable materials mayinclude, but are not limited to, carbon, carbon and an organic binder,platinum, palladium, carbon, indium oxide, tin oxide, mixed indium/tinoxides, gold, silver, iridium, and mixtures thereof. These materials maybe formed into electrode structures by any suitable method, for example,by sputtering, vapor coating, screen printing, thermal evaporation,gravure printing, slot coating or lithography. In preferred embodiments,the material is sputtered or screen-printed to form the electrodestructures.

Non-limiting examples of materials preferred for use in referenceelectrodes include metal/metal salt systems such as silver in contactwith silver chloride, silver bromide or silver iodide, and mercury incontact mercurous chloride or mercurous sulfate. The metal may bedeposited by any suitable method and then brought into contact with theappropriate metal salt. Suitable methods include, for example,electrolysis in a suitable salt solution or chemical oxidation. Suchmetal/metal salt systems provide better potential control inpotentiometric measurement methods than do single metal componentsystems. In a preferred embodiment, the metal/metal salt electrodesystems are preferred as a separate reference electrode in anamperometric sensor.

Any suitable electrode spacing may be used. In certain embodiments itmay be preferred that the electrodes be separated by a distance of about500 μm, 400 μm, 300 μm, 200 μm, 100 μm, 50 μm, 200 μm, 10 μm, or less.In other embodiments it may be preferred that the electrodes beseparated by a distance of about 500 μm, 600 μm, 700 μm, 800 μm, 900 μm,1 mm, or more.

Lysing Agents

In certain embodiments, it may be desired to include one or more lysingagents in the electrochemical cell. Suitable lysing agents includedetergents, both ionic and non-ionic, proteolytic enzymes, and lipases.Suitable ionic detergents include, for example, sodium dodecyl sulfateand cetyl trimethylammonium bromide. Non-limiting examples ofproteolytic enzymes include trypsin, chymotrypsin, pepsin, papain, andPronase E, a very active enzyme having broad specificity. Nonionicsurfactants suitable for use include, for example, ethoxylatedoctylphenols, including the TRITON X™ Series available from Rohm & Haasof Philadelphia, Pa. In a preferred embodiment, saponins, namely, plantglycosides that foam in water, are preferred as the lysing agent. In aparticularly preferred embodiment, alkali metal salts of deoxycholicacid, available from Sigma Aldrich Pty. Ltd. of Castle Hill, NSW,Australia, are preferred as lysing agents.

Redox Reagent

Redox reagents may also be included in the electrochemical cell inpreferred embodiments. Preferred redox reagents for use inelectrochemical cells for measuring glucose in blood include those whichare capable of oxidizing the reduced form of enzymes that are capable ofselectively oxidizing glucose. Examples of suitable enzymes include, butare not limited to, glucose oxidase dehydrogenase, PQQ dependent glucosedehydrogenase, and NAD dependent glucose dehydrogenase. Examples ofredox reagents suitable for use in analyzing glucose include, but arenot limited, to salts of ferricyanide, dichromate, vanadium oxides,permanganate, and electroactive organometallic complexes. Organic redoxreagents such as dichlorophenolindophenol, and quinones are alsosuitable. In a preferred embodiment, the redox reagent for analyzingglucose is ferricyanide.

Buffers

Optionally, a buffer may be present along with a redox reagent in driedform in the electrochemical cell. If a buffer is present, it is presentin an amount such that the resulting pH level is suitable for adjustingthe oxidizing potential of the redox reagent to a level suitable foroxidizing, for example, glucose but not other species that it is notdesired to detect. The buffer is present in a sufficient amount so as tosubstantially maintain the pH of the sample at the desired level duringthe test. Examples of suitable buffers include phosphates, carbonates,alkali metal salts of mellitic acid, alkali metal salts of citric acid,and alkali metal salts of citraconic acid. The choice of buffer maydepend, amongst other factors, on the desired pH. The buffer is selectedso as not to react with the redox reagent.

Inert Salts

Inert salts preferred for use in various embodiments include salts thatdissociate to form ions in the sample to be analyzed, but do not reactwith any of the redox reagents or other substances in the sample or inthe cell, including with the cell electrodes. Examples of suitable inertsalts include, but are not limited to, alkali metal chlorides, nitrates,sulfates, and phosphates.

Other Substances Present Within the Cell

In addition to redox reagents and buffers, other substances may also bepresent within the electrochemical cell. Such substances include, forexample, viscosity enhancers and low molecular weight polymers.Hydrophilic substances may also be contained within the cell, such aspolyethylene glycol, polyacrylic acid, dextran, and surfactants such asthose marketed by Rohm & Haas Company of Philadelphia, Pa., under thetrade name TRITON™ or by ICI Americas Inc. of Wilmington, Del., underthe trade name TWEEN™. In a preferred embodiment Pluronic surfactantsand antifoaming agents available from BASF are present. Such substancesmay enhance the fill rate of the cell, provide a more stablemeasurement, and inhibit evaporation in small volume samples.

Electrical Circuit

The electrically conductive layers are preferably connected via theconnectors described herein to electrical circuits capable of applyingpotentials between the electrodes and measuring the resulting currents,for example, meters. Suitable meters may include one or more of a powersource, circuitry for applying controlled potentials or currents, amicroprocessor control device, computer, or data storage device, adisplay device, an audible alarm device, or other devices or componentsas are known in the art. The meter may also be capable of beinginterfaced to a computer or data storage device. For example, a typicalmeter may be a hand-held device that is powered by a battery, controlledby an on-board microprocessor, and contains circuitry for applyingpredetermined potentials or currents between, for example, stripelectrode connection pins and circuitry such as an analog-to-digitalconverter. In this embodiment, the analog signal from the strip may beconverted to a digital signal that can be analyzed and/or stored by amicroprocessor. The meter may also contain a display such as a LiquidCrystal Display and suitable associated circuitry to display the resultof the test to the user. In an alternative embodiment, the meter mayincorporate specialized circuitry, such as potential application andsignal acquisition circuitry. Such specialized circuitry may beincorporated in a separate module that may be interfaced with a genericcomputing device, such as a hand-held computer or other type ofcomputer. In such an embodiment, the generic device may perform thecontrol, analysis, data storage, and/or display functions. Such anembodiment allows for a less expensive meter to be produced because thegeneric computing device may be preferred for many functions and as suchis not considered as part of the cost of the electrochemical measurementsystem. In either of these meter embodiments, the meter or genericcomputing device may be capable of communication with external devicessuch as local computer networks or the Internet to facilitate thedistribution of test results and the provision of system upgrades to theuser.

The above description provides several methods and materials of thepresent invention. This invention is susceptible to modifications in themethods and materials, as well as alterations in the fabrication methodsand equipment. Such modifications will become apparent to those skilledin the art from a consideration of this disclosure or practice of theinvention provided herein. Consequently, it is not intended that thisinvention be limited to the specific embodiments provided herein, butthat it cover all modifications and alternatives coming within the truescope and spirit of the invention as embodied in the attached claims.All references cited herein are hereby incorporated by reference intheir entireties.

1. A method for forming an electrical connection between anelectrochemical cell and a meter, the method comprising the steps of: a)providing an electrochemical cell, the electrochemical cell comprising afirst insulating substrate carrying a first electrically conductivecoating, a second insulating substrate carrying a second electricallyconductive coating, and an insulating spacer layer disposedtherebetween, the electrically conductive coatings being disposed toface each other in a spaced apart relationship, wherein an edge of thefirst insulating substrate carrying the first electrically conductivecoating extends beyond an edge of the second insulating substratecarrying the second electrically conductive coating and beyond an edgeof the insulating spacer layer, and wherein the edge of the secondinsulating substrate carrying the second electrically conductive coatingextends beyond the edge of the insulating spacer layer; b) providing ameter, the meter comprising a wedge, the wedge comprising an upper wedgeconductive surface and a lower wedge conductive surface, the conductivesurfaces in electrical communication with the meter; and c) inserting aportion of the electrochemical cell into the meter, whereby the wedge isinserted between the portion of the first insulating substrate carryingthe first electrically conductive coating and the portion of the secondinsulating substrate carrying the second electrically conductive coatingthat extends beyond the edge of the insulating spacer layer, whereby anelectrical connection between the first electrically conductive coatingand the lower wedge conductive surface is formed, and whereby anelectrical connection between the second electrically conductive coatingand the upper wedge conductive surface is formed.
 2. The method of claim1, the meter further comprising a pivot point, wherein the wedge iscapable of rotating on the pivot point.